Method for preparing multi-layer optical laminates

ABSTRACT

Methods for preparing multi-layer optical laminates include placing an optical film that is free form an adhesive layer between first and second glass substrates that are free of an adhesive layer, placing this laminate under vacuum, and then heating the laminate under pressure to a temperature above the softening temperature of the optical film. The glass substrates are free of an adhesive layer but may include a silane surface treatment. The resulting multi-layer laminate is optically clear and does not show scattering of reflected light by the optical film.

FIELD OF THE DISCLOSURE

This disclosure relates to methods for preparing multi-layer opticallaminates, and optical laminates.

BACKGROUND

Multi-layer optical laminates are optical constructions that includethree or more material layers adhered together. These optical laminatesmay be articles, meaning that they are used as they are, or they may becombined with other layers or constructions to form articles. Thelaminates can take a wide variety of shapes and forms. In someinstances, the multi-layer optical laminates, may contain a combinationof relatively rigid or semi-rigid layers such as glass or polymericplates and flexible layers such as films. A wide variety of methods canbe used to adhere together the layers, often adhesive layers are used.

An example of a multi-layer optical laminate is the safety glass that istypically used in the windshields of automobiles. In order to preventthe glass windshield from shattering, generally the safety glassconstruction is a multi-layer article with two layers of glass and anoptically clear film sandwiched between the two layers of glass.Frequently the film is adhered to the glass by a heat activated adhesivelayer such as polyvinyl butyral (PVB). PVB is particularly suitable asit is optically clear and is not tacky at room temperature, allowing itto be handled as a free-standing film at room temperature, but uponheating it becomes tacky and bonds strongly to both the glass and thefilm. Typically the safety glass laminates of glass/PVB/film/PVB/glassare prepared and placed in an autoclave and subjected to heat andpressure to form the laminate article. A variation on this process isdescribed in US Patent Publication No. 2010/0285310 (Izurani et al.)which describes making a plastic film-inserted laminated glass, by firstmaking a laminated film by thermocompression bonding and laminating thelaminated film between curved glass plates.

SUMMARY

Disclosed herein are methods of preparing multi-layer optical laminatesand multi-layer optical laminates. In some embodiments the method ofpreparing a laminate article comprises providing a first glass substratewith a first major surface and a second major surface, wherein thesecond major surface is free from an adhesive layer; providing a secondglass substrate with a first major surface and a second major surface,wherein the first major surface is free from an adhesive layer;providing a first optical film with a first major surface and a secondmajor surface comprising one or more layers of polymeric material andwherein the first major surface and the second major surface are freefrom an adhesive layer; preparing a multi-layer construction byarranging the first glass substrate, the first optical film, and thesecond glass substrate such that the second major surface of the firstglass substrate is proximate to the first major surface of the firstoptical film, and the second major surface of the first optical film isproximate to the first major surface of the second glass substrate;placing the multi-layer construction in a vacuum chamber; applying avacuum to the vacuum chamber containing the multi-layer construction,such that the second major surface of the first glass substrate is indirect surface contact with the first major surface of the first opticalfilm and the first major surface of the second glass substrate is indirect surface contact with the second major surface of the firstoptical film; releasing the vacuum from the vacuum chamber; removing themulti-layer construction from the vacuum chamber and place themulti-layer construction in a device capable of supplying heat and/orpressure; raising and holding the temperature of the device capable ofsupplying heat and/or pressure to a temperature at or above thesoftening temperature of the polymeric material of the first and secondmajor surfaces of the first optical film while applying a pressure ofgreater than atmospheric pressure to the multi-layer construction;decreasing the temperature of the device capable of supplying heatand/or pressure to room temperature; and releasing the pressure ofgreater than atmospheric pressure to the multi-layer construction, toform a multi-layer article that is optically clear and does not showscattering of reflected light by the first optical film.

In other embodiments, the method of preparing a laminate articlecomprises providing a first glass substrate with a first major surfaceand a second major surface, wherein the second major surface is atreated surface that is free from an adhesive layer; providing a secondglass substrate with a first major surface and a second major surface,wherein the first major surface is a treated surface that is free froman adhesive layer; providing a first optical film with a first majorsurface and a second major surface comprising one or more layers ofpolymeric material and wherein the first major surface and the secondmajor surface are free from an adhesive layer; preparing a multi-layerconstruction by arranging the first glass substrate, the first opticalfilm, and the second glass substrate such that the second major surfaceof the first glass substrate is proximate to the first major surface ofthe first optical film, and the second major surface of the firstoptical film is proximate to the first major surface of the second glasssubstrate; placing the multi-layer construction in a vacuum chamber;applying a vacuum to the vacuum chamber containing the multi-layerconstruction, such that the second major surface of the first glasssubstrate is in direct surface contact with the first major surface ofthe first optical film and the first major surface of the second glasssubstrate is in direct surface contact with the second major surface ofthe first optical film; releasing the vacuum from the vacuum chamber;removing the multi-layer construction from the vacuum chamber and placethe multi-layer construction in a device capable of supplying heatand/or pressure; raising and holding the temperature of the devicecapable of supplying heat and/or pressure to a temperature at or abovethe softening temperature of the polymeric material of the first andsecond major surfaces of the first optical film while applying apressure of greater than atmospheric pressure to the multi-layerconstruction; decreasing the temperature of the device capable ofsupplying heat and/or pressure to room temperature; and releasing thepressure of greater than atmospheric pressure to the multi-layerconstruction, to form a multi-layer article that is optically clear anddoes not show scattering of reflected light by the first optical film.

Also disclosed are multi-layer articles. In some embodiments, themulti-layer article comprises a first glass substrate with a first majorsurface and a second major surface; a second glass substrate with afirst major surface and a second major surface; and a first optical filmwith a first major surface and a second major surface comprising one ormore layers of polymeric material, wherein the second major surface ofthe first glass substrate is interfacially bonded to the first majorsurface of the first optical film, wherein the interfacial bond is freefrom an adhesive layer, and wherein the second major surface of thefirst optical film is interfacially bonded with the first major surfaceof the second glass substrate, wherein the interfacial bond is free froman adhesive layer, and wherein the second major surface to the firstglass substrate and the first major surface of the second glasssubstrate is a treated or untreated surface, wherein the treated surfacecomprises a silane coupling agent-treated surface, and wherein themulti-layer article is optically clear and does not show scattering ofreflected light by the first optical film.

BRIEF DESCRIPTION OF THE DRAWINGS

The present application may be more completely understood inconsideration of the following detailed description of variousembodiments of the disclosure in connection with the accompanyingdrawings.

FIG. 1 is a cross sectional view of an embodiment of a method of thepresent disclosure.

FIG. 2 is a cross sectional view of another embodiment of a method ofthe present disclosure.

FIG. 3 is a cross sectional view of yet another embodiment of a methodof the present disclosure.

In the following description of the illustrated embodiments, referenceis made to the accompanying drawings, in which is shown by way ofillustration, various embodiments in which the disclosure may bepracticed. It is to be understood that the embodiments may be utilizedand structural changes may be made without departing from the scope ofthe present disclosure. The figures are not necessarily to scale. Likenumbers used in the figures refer to like components. However, it willbe understood that the use of a number to refer to a component in agiven figure is not intended to limit the component in another figurelabeled with the same number.

DETAILED DESCRIPTION

Multi-layer optical laminates are optical constructions that includethree or more material layers adhered together. These optical laminatesmay be articles, meaning that they are used as they are, or they may becombined with other layers or constructions to form articles. Thelaminates can take a wide variety of shapes and forms. In someinstances, the multi-layer optical laminates, may contain a combinationof relatively rigid or semi-rigid layers such as glass or polymericplates and flexible layers such as films. A wide variety of methods canbe used to adhere together the layers, often adhesive layers are used.

As more and more complex multi-layer optical laminates are developed andused, the requirements for these laminates have become more stringent.Not only do the laminates have structural limitations, namely theycannot delaminate or otherwise structurally fail, but also they havemust have high optical transparency and this transparency must remainthrough a variety of conditions, in other words they must not developoptical defects. The development of optical defects, such as bubbles,local delamination, cloudiness and discoloration in laminated glass areunwanted phenomena that negatively affect the visual quality of alaminate but do not affect its structural safety. These defects canarise due to numerous influences during the production of a laminateand/or can be triggered during its lifetime.

Many of these defects can be dealt with through the use of adhesivelayers.

However, one defect in optical laminates that can be created by the useof adhesive layers is the phenomenon described as “orange peel”. Manydisciplines use the term orange peel defect to describe a variety ofdifferent circumstances, such as a roughened surface of a metal sheet onan automobile, or the roughened surface of a lens that has beenimproperly ground. In the field of optical laminates it has a somewhatdifferent, but related, meaning. One useful description of the orangepeel defect in optical laminates is presented in paragraph [0008] of USPatent Publication No. 2014/0220286 (Honeycutt et al.). This paragraphdescribes the circumstance where a PET (polyethylene terephthalate) filmis laminated between glass plates through the use of polyvinyl butyral(PVB). The description states: “An additional problem associated with alaminate comprising a PET layer between two PVB sheets is the formationof another type of optical distortion referred to as waviness or orangepeel. When PET is laminated between two layers of PVB, the PET does not“flow” like the PVB does, so it may look wavy or appear to have asurface that looks like applesauce when laminated, even if there isexcellent deairing of the laminate.” In some instances, the orange peeleffect may not appear as a visual defect noticeable to the naked eye,but when light passes through the laminate, the exiting light can have anon-smooth surface. This can be observed by observing the reflectedimage of a straight body, such as a fluorescent tube, from the laminate.Whereas the reflection of the straight body light should have a smoothsurface, in instances demonstrating orange peel, the surface of thereflection of straight body light has a textured or wavy surface.Therefore it is desirable to have multi-layer laminates that show low orno scattering of reflected light by films contained in the laminateconstruction.

The present disclosure provides methods for preparing multi-layeroptical laminates that are free from defects such as orange peel, by notutilizing adhesive layers to laminate films between optical substratessuch as glass. In the present disclosure, films are laminated directlyto glass and the films serve to adhere the optical substrates togetherwithout generating optical defects such as orange peel.

Unless otherwise indicated, all numbers expressing feature sizes,amounts, and physical properties used in the specification and claimsare to be understood as being modified in all instances by the term“about.” Accordingly, unless indicated to the contrary, the numericalparameters set forth in the foregoing specification and attached claimsare approximations that can vary depending upon the desired propertiessought to be obtained by those skilled in the art utilizing theteachings disclosed herein. The recitation of numerical ranges byendpoints includes all numbers subsumed within that range (e.g. 1 to 5includes 1, 1.5, 2, 2.75, 3, 3.80, 4, and 5) and any range within thatrange.

As used in this specification and the appended claims, the singularforms “a”, “an”, and “the” encompass embodiments having pluralreferents, unless the content clearly dictates otherwise. For example,reference to “a layer” encompasses embodiments having one, two or morelayers. As used in this specification and the appended claims, the term“or” is generally employed in its sense including “and/or” unless thecontent clearly dictates otherwise.

As used herein, the term “adjacent” refers to two layers that areproximate to another layer. Layers that are adjacent may be in directcontact with each other, or there may be an intervening layer. There isno empty space between layers that are adjacent.

The terms “room temperature” and “ambient temperature” are usedinterchangeably and have their conventional meaning, that is to sayrefer to temperature of 20-25° C.

Unless otherwise indicated, “optically transparent” refers to a layer,film, or article that has a high light transmittance over at least aportion of the visible light spectrum (about 400 to about 700 nm).Typically optically transparent layers, films, or articles have aluminous transmission of at least 90%.

Unless otherwise indicated, “optically clear” refers to an layer, film,or article that has a high light transmittance over at least a portionof the visible light spectrum (about 400 to about 700 nm), and thatexhibits low haze. Typically optically clear layers, films, or articleshave visible light transmittance values of at least 90%, often at least95%, and haze values of 5% or less, often 2% or less. Luminoustransmission and haze can be measured using techniques such as aredescribed in ASTM D1003-11.

The term “alkyl” refers to a monovalent group that is a radical of analkane, which is a saturated hydrocarbon. The alkyl can be linear,branched, cyclic, or combinations thereof and typically has 1 to 20carbon atoms. In some embodiments, the alkyl group contains 1 to 18, 1to 12, 1 to 10, 1 to 8, 1 to 6, or 1 to 4 carbon atoms. Examples ofalkyl groups include, but are not limited to, methyl, ethyl, n-propyl,isopropyl, n-butyl, isobutyl, tert-butyl, n-pentyl, n-hexyl, cyclohexyl,n-heptyl, n-octyl, and ethylhexyl.

The term “aryl” refers to a monovalent group that is aromatic andcarbocyclic. The aryl can have one to five rings that are connected toor fused to the aromatic ring. The other ring structures can bearomatic, non-aromatic, or combinations thereof. Examples of aryl groupsinclude, but are not limited to, phenyl, biphenyl, terphenyl, anthryl,naphthyl, acenaphthyl, anthraquinonyl, phenanthryl, anthracenyl,pyrenyl, perylenyl, and fluorenyl.

The term “alkylene” refers to a divalent group that is a radical of analkane. The alkylene can be straight-chained, branched, cyclic, orcombinations thereof. The alkylene often has 1 to 20 carbon atoms. Insome embodiments, the alkylene contains 1 to 18, 1 to 12, 1 to 10, 1 to8, 1 to 6, or 1 to 4 carbon atoms. The radical centers of the alkylenecan be on the same carbon atom (i.e., an alkylidene) or on differentcarbon atoms.

The term “arylene” refers to a divalent group that is carbocyclic andaromatic. The group has one to five rings that are connected, fused, orcombinations thereof. The other rings can be aromatic, non-aromatic, orcombinations thereof In some embodiments, the arylene group has up to 5rings, up to 4 rings, up to 3 rings, up to 2 rings, or one aromaticring. For example, the arylene group can be phenylene.

The term “aralkylene” refers to a divalent group of formula—R^(a)—Ar^(a)— where R^(a) is an alkylene and Ar^(a) is an arylene(i.e., an alkylene is bonded to an arylene).

The term “alkoxy” refers to a monovalent group of formula —O—R, where Ris an alkyl group.

Disclosed herein are methods of preparing a laminate articles. Thesemethods comprise forming a multi-layer construction, placing themulti-layer construction in a vacuum chamber, applying a vacuum to thevacuum chamber containing the multi-layer construction, releasing thevacuum from the vacuum chamber, removing the multi-layer constructionfrom the vacuum chamber and placing the multi-layer construction in adevice capable of supplying heat and/or pressure, raising and holdingthe temperature while applying a pressure of greater than atmosphericpressure to the multi-layer construction, and later decreasing thetemperature and releasing the pressure to form a multi-layer articlethat is optically clear.

The multi-layer construction is prepared by providing a first glasssubstrate with a first major surface and a second major surface, wherethe second major surface is free from an adhesive layer, providing asecond glass substrate with a first major surface and a second majorsurface, where the first major surface is free from an adhesive layer,and providing a first optical film with a first major surface and asecond major surface where the first major surface and the second majorsurface are free from an adhesive layer. The first optical filmcomprises one or more layers of polymeric material. The multi-layerconstruction is prepared by arranging the first glass substrate, thefirst optical film, and the second glass substrate such that the secondmajor surface of the first glass substrate is proximate to the firstmajor surface of the first optical film, and the second major surface ofthe first optical film is proximate to the first major surface of thesecond glass substrate.

Upon removal of the multi-layer construction from the vacuum chamber,the second major surface of the first glass substrate is in directsurface contact with the first major surface of the first optical filmand the first major surface of the second glass substrate is in directsurface contact with the second major surface of the first optical film.

When the multi-layer construction is placed in a device capable ofsupplying heat and/or pressure, the temperature is raised and held at orabove the softening temperature of the polymeric material of the firstand second major surfaces of the first optical film. If the polymericmaterial of the first and second major surfaces of the first opticalfilm comprise different materials, the temperature is raised and held ator above the higher softening temperature of the different materials.

The multi-layer construction may be assembled in a variety of ways priorto being placed in the vacuum chamber. In some embodiments, preparingthe multi-layer construction comprises placing the first and secondglass substrates and the first optical film in a frame wherein the framecomprises first and second plates such that the first plate is incontact with the first major surface of the first glass substrate andthe second plate is in contact with second major surface of the secondglass substrate. In some of these embodiments, each plate contains atleast one orifice, where the orifice is connected to a source ofcompressed air pressure and wherein the orifice in the first plate is influid contact with the first glass substrate and the orifice in thesecond plate is in fluid contact with the second glass substrate, suchthat applying a pressure of greater than atmospheric pressure to themulti-layer construction comprises applying compressed air pressurethrough the orifices in the first and second plates.

A wide variety of glass substrates are suitable. The glass substratesare of sufficient thickness to make them rigid substrates and areoptically clear. The thickness of the glass substrates depends upon avariety of factors such as the desired total thickness of the formedmulti-layer article. Typically it is desirable that the formedmulti-layer article have a thickness of no more than 2.5 millimeters.

A wide variety of optical films are suitable for use in the methods ofthis disclosure. As used herein, the term “optical film” refers to afilm that can be used to produce an optical effect. The optical filmsare typically polymer-containing films that can be a single layer ormultiple layers. The optical films are flexible and can be of anysuitable thickness. The optical films often are at least partiallytransmissive, reflective, antireflective, polarizing, optically clear,or diffusive with respect to some wavelengths of the electromagneticspectrum (e.g., wavelengths in the visible, ultraviolet, or infraredregions of the electromagnetic spectrum). Exemplary optical filmsinclude, but are not limited to, visible mirror films, color mirrorfilms, solar reflective films, infrared reflective films, ultravioletreflective films, brightness enhancement films, reflective polarizerfilms such as dual brightness enhancement films, absorptive polarizerfilms, optically clear films, tinted films, and antireflective films.

Some optical films have multiple layers such as multiple layers ofpolymer-containing materials (e.g., polymers with or without dyes) ormultiple layers of metal-containing material and polymeric materials.Some optical films have alternating layers of polymeric material withdifferent indexes of refraction. Other optical films have alternatingpolymeric layers and metal-containing layers. Exemplary optical filmsare described in the following patents: U.S. Pat. No. 6,049,419(Wheatley et al.); U.S. Pat. No. 5,223,465 (Wheatley et al.); U.S. Pat.No. 5,882,774 (Jonza et al.); U.S. Pat. No. 6,049,419 (Wheatley et al.);U.S. Pat. No. RE 34,605 (Schrenk et al.); U.S. Pat. No.

5,579,162 (Bjornard et al.); and U.S. Pat. No. 5,360,659 (Arends etal.).

In some particularly suitable embodiments, the first optical filmcomprises a multi-layer polarizing film. A wide variety of such filmsare suitable. Among the suitable multi-layer polarizing films are onescomprising alternating layers of polyethylene terephthalate andpolyethylene-naphthalate.

A wide variety of temperatures and pressures can be used to themulti-layer optical laminates of this disclosure. In some embodiments,it may be desirable to raise and hold the temperature of the devicecapable of supplying heat and/or pressure to a temperature of at least120° C. for at least 30 minutes. In other embodiments, it may bedesirable to raise and hold the temperature of the device capable ofsupplying heat and/or pressure to a temperature of at least 150° C. forat least 1 hour. A wide range of pressures are also suitable. In somespecific embodiments, the pressure is at least 5 Kg/cm².

In some embodiments, the method further comprises providing a thirdglass substrate with a first major surface and second major surface,where the first major surface of the third glass substrate is free froman adhesive layer, providing a second optical film with a first majorsurface and a second major surface, where the first major surface andthe second major surface are free from an adhesive layer. In theseembodiments, preparing the multi-layer construction further comprisesarranging the second optical film and the third glass substrate suchthat the first major surface of the second optical film is proximate tothe second major surface of the second glass substrate and the secondmajor surface of the second optical film is proximate to the first majorsurface of the third glass substrate. The second optical film, like thefirst optical film comprises one or more layers of polymeric material.The first optical film and the second optical film may be the same, buttypically they are different films. If the polymeric material of thefirst and second optical films comprise different materials, thetemperature is raised and held at or above the higher softeningtemperature of the different materials.

In other embodiments, the method further comprises providing a thirdglass substrate with a first major surface and second major surface,where the first major surface of the third glass substrate is free froman adhesive layer, providing a second optical film with a first majorsurface and a second major surface, where the first major surface andthe second major surface are free from an adhesive layer, providing athird optical film with a first major surface and a second majorsurface, where the first major surface and the second major surface arefree from an adhesive layer. In these embodiments, preparing themulti-layer construction further comprises arranging the second opticalfilm, the third optical film, and the third glass substrate such thatthe first major surface of the second optical film is proximate to thesecond major surface of the second glass substrate, the first majorsurface of the third optical film is proximate to the second majorsurface of the second optical film, and the second major surface of thethird optical film is proximate to the first major surface of the thirdglass substrate. The second and third optical films, like the firstoptical film comprise one or more layers of polymeric material. Thefirst, second, and third optical film may be the same, but typicallythey are different films. If the polymeric material of the optical filmscomprise different materials, the temperature is raised and held at orabove the higher softening temperature of the different materials.

In the embodiments that include additional films and glass substrates,the overall methodology remains the same. In these embodiments, themulti-layer construction is prepared and process in the same way asdescribed above.

Also disclosed herein are methods of preparing laminate articles whereone or more of the surfaces of the glass substrates involved in formingthe laminate are treated surfaces. The treated surfaces are still freeof adhesive layers. A variety of surface treatments are suitable forforming the treated surfaces.

The methods are similar to the methods described above. These methodscomprise forming a multi-layer construction, placing the multi-layerconstruction in a vacuum chamber, applying a vacuum to the vacuumchamber containing the multi-layer construction, releasing the vacuumfrom the vacuum chamber, removing the multi-layer construction from thevacuum chamber and placing the multi-layer construction in a devicecapable of supplying heat and/or pressure, raising and holding thetemperature while applying a pressure of greater than atmosphericpressure to the multi-layer construction, and later decreasing thetemperature and releasing the pressure to form a multi-layer articlethat is optically clear.

The multi-layer construction is prepared by providing a first glasssubstrate with a first major surface and a second major surface, wherehe second major surface is a treated surface that is free from anadhesive layer, providing a second glass substrate with a first majorsurface and a second major surface, where the first major surface is atreated surface that is free from an adhesive layer, and providing afirst optical film with a first major surface and a second major surfacewhere the first major surface and the second major surface are free froman adhesive layer. The first optical film comprises one or more layersof polymeric material. The multi-layer construction is prepared byarranging the first glass substrate, the first optical film, and thesecond glass substrate such that the second major surface of the firstglass substrate is proximate to the first major surface of the firstoptical film, and the second major surface of the first optical film isproximate to the first major surface of the second glass substrate.

Upon removal of the multi-layer construction from the vacuum chamber,the second major surface of the first glass substrate is in directsurface contact with the first major surface of the first optical filmand the first major surface of the second glass substrate is in directsurface contact with the second major surface of the first optical film.

When the multi-layer construction is placed in a device capable ofsupplying heat and/or pressure, the temperature is raised and held at orabove the softening temperature of the polymeric material of the firstand second major surfaces of the first optical film. If the polymericmaterial of the first and second major surfaces of the first opticalfilm comprise different materials, the temperature is raised and held ator above the higher softening temperature of the different materials.

The multi-layer construction may be assembled in a variety of ways priorto being placed in the vacuum chamber. In some embodiments, preparingthe multi-layer construction comprises placing the first and secondglass substrates and the first optical film in a frame wherein the framecomprises first and second plates such that the first plate is incontact with the first major surface of the first glass substrate andthe second plate is in contact with second major surface of the secondglass substrate. In some of these embodiments, each plate contains atleast one orifice, where the orifice is connected to a source ofcompressed air pressure and wherein the orifice in the first plate is influid contact with the first glass substrate and the orifice in thesecond plate is in fluid contact with the second glass substrate, suchthat applying a pressure of greater than atmospheric pressure to themulti-layer construction comprises applying compressed air pressurethrough the orifices in the first and second plates.

A wide variety of glass substrates are suitable. The glass substratesare of sufficient thickness to make them rigid substrates and areoptically clear. The thickness of the glass substrates depends upon avariety of factors such as the desired total thickness of the formedmulti-layer article. Typically it is desirable that the formedmulti-layer article have a thickness of no more than 2.5 millimeters.

In some particularly suitable embodiments, the first optical filmcomprises a multi-layer polarizing film. A wide variety of such filmsare suitable. Among the suitable multi-layer polarizing films are onescomprising alternating layers of polyethylene terephthalate andpolyethylene-naphthalate.

A wide variety of temperatures and pressures can be used to themulti-layer optical laminates of this disclosure. In some embodiments,it may be desirable to raise and hold the temperature of the devicecapable of supplying heat and/or pressure to a temperature of at least120° C. for at least 30 minutes. In other embodiments, it may bedesirable to raise and hold the temperature of the device capable ofsupplying heat and/or pressure to a temperature of at least 150° C. forat least 1 hour. A wide range of pressures are also suitable. In somespecific embodiments, the pressure is at least 5 Kg/cm².

In some embodiments, the method further comprises providing a thirdglass substrate with a first major surface and second major surface,where the first major surface of the third glass substrate is a treatedsurface that is free from an adhesive layer, providing a second opticalfilm with a first major surface and a second major surface, where thefirst major surface and the second major surface are free from anadhesive layer. In these embodiments, preparing the multi-layerconstruction further comprises arranging the second optical film and thethird glass substrate such that the first major surface of the secondoptical film is proximate to the second major surface of the secondglass substrate and the second major surface of the second optical filmis proximate to the first major surface of the third glass substrate.The second optical film, like the first optical film comprises one ormore layers of polymeric material. The first optical film and the secondoptical film may be the same, but typically they are different films. Ifthe polymeric material of the first and second optical films comprisedifferent materials, the temperature is raised and held at or above thehigher softening temperature of the different materials.

In other embodiments, the method further comprises providing a thirdglass substrate with a first major surface and second major surface,where the first major surface of the third glass substrate is a treatedsurface that is free from an adhesive layer, providing a second opticalfilm with a first major surface and a second major surface, where thefirst major surface and the second major surface are free from anadhesive layer, providing a third optical film with a first majorsurface and a second major surface, where the first major surface andthe second major surface are free from an adhesive layer. In theseembodiments, preparing the multi-layer construction further comprisesarranging the second optical film, the third optical film, and the thirdglass substrate such that the first major surface of the second opticalfilm is proximate to the second major surface of the second glasssubstrate, the first major surface of the third optical film isproximate to the second major surface of the second optical film, andthe second major surface of the third optical film is proximate to thefirst major surface of the third glass substrate. The second and thirdoptical films, like the first optical film comprise one or more layersof polymeric material. The first, second, and third optical film may bethe same, but typically they are different films. If the polymericmaterial of the optical films comprise different materials, thetemperature is raised and held at or above the higher softeningtemperature of the different materials.

In the embodiments that include additional films and glass substrates,the overall methodology remains the same. In these embodiments, themulti-layer construction is prepared and process in the same way asdescribed above.

A wide variety of surface treatments are suitable in the methods of thisdisclosure. In some embodiments, the treated surface of the first,second, and third glass substrates are prepared by a treatmentcomprising providing a treatment solution, applying the treatmentsolution to the glass surface to form a continuous or discontinuouscoating layer, and drying the continuous or discontinuous coating layer.The treatment solution comprises at least one silane coupling agent, anda solvent.

A wide variety of silane coupling agents are suitable. Particularlysuitable silane coupling agents are those of the general structure:Z₃Si-A-X, where each Z is an alkyl or alkoxy group, with the provisothat at least one Z is an alkoxy group; A is a divalent linking groupcomprising an alkylene, arylene, or aralkylene group; and X is afunctional group selected from: an amino group —NR¹ ₂ where each R¹independently is a hydrogen atom, an alkyl group, or an aryl group; anisocyanate group; or an epoxy group.

A wide variety of solvents are suitable for preparing the treatmentsolution, provided the solvent is able to solubilize the silane couplingagent and is sufficiently volatile as to be readily removed by drying.Suitable solvents include: ketones such as acetone or MEK (methyl ethylketone); aromatic liquids such as benzene or toluene; esters such asethyl acetate; alkanes such as hexane or heptane; alcohols such amethanol, ethanol, or propanol; ethers such as ethyl ether or THF(tetrahydrofuran); or halogenated alkanes such a methylene chloride orcarbon tetrachloride.

Also disclosed are multi-layer articles that are prepared using themethods described above. In some embodiments, the multi-layer articlecomprises a first glass substrate with a first major surface and asecond major surface, a second glass substrate with a first majorsurface and a second major surface, and a first optical film with afirst major surface and a second major surface comprising one or morelayers of polymeric material, wherein the second major surface of thefirst glass substrate is interfacially bonded to the first major surfaceof the first optical film, wherein the interfacial bond is free from anadhesive layer, and wherein the second major surface of the firstoptical film is interfacially bonded with the first major surface of thesecond glass substrate, wherein the interfacial bond is free from anadhesive layer, and wherein the second major surface to the first glasssubstrate and the first major surface of the second glass substrate is atreated or untreated surface, wherein the treated surface comprises asilane coupling agent-treated surface, and wherein the multi-layerarticle is optically clear.

In other embodiments, the multi-layer article further comprises a secondoptical film with a first major surface and a second major surface, anda third glass substrate with a first major surface and a second majorsurface, where the second major surface of the second glass substrate isinterfacially bonded to the first major surface of the second opticalfilm, wherein the interfacial bond is free from an adhesive layer, andwherein the second major surface of the second optical film isinterfacially bonded with the first major surface of the third glasssubstrate, where the interfacial bond is free from an adhesive layer,and wherein the second major surface of the second glass substrate andthe first major surface of the third glass substrate is a treated oruntreated surface, wherein the treated surface comprises a silanecoupling agent-treated surface, and wherein the multi-layer article isoptically clear and does not show scattering of reflected light by thefirst optical film.

In yet other embodiments, the multi-layer article further comprises asecond optical film with a first major surface and a second majorsurface, a third optical film with a first major surface and a secondmajor surface, and a third glass substrate with a first major surfaceand a second major surface, where the second major surface of the secondglass substrate is interfacially bonded to the first major surface ofthe second optical film, wherein the interfacial bond is free from anadhesive layer, and where the second major surface of the second opticalfilm is interfacially bonded with the first major surface of the thirdoptical film, where the interfacial bond is free from an adhesive layer,and where the second major surface of the third optical film isinterfacially bonded to the first major surface of the third glasssubstrate, where the second major surface of the second glass substrateand the first major surface of the third glass substrate is a treated oruntreated surface, where the treated surface comprises a silane couplingagent-treated surface, and wherein the multi-layer article is opticallyclear and does not show scattering of reflected light by the opticalfilms.

Suitable glass substrates, optical films, and surface treatments aredescribed in detail above. In some embodiments, the first optical filmcomprises a multi-layer polarizing film. In some of these embodiments,the multi-layer polarizing film comprises alternating layers ofpolyethylene terephthalate and polyethylene-naphthalate.

In embodiments where one or more of the glass substrates comprise atreated surface, the treated surface comprises a treated surface treatedwith a silane coupling agent with the general structure: Z₃Si-A-X, whereeach Z is an alkyl or alkoxy group, with the proviso that at least one Zis an alkoxy group; A is a divalent linking group comprising analkylene, arylene, or aralkylene group; and X is a functional groupselected from: an amino group —NR¹ ₂ where each R¹ independently is ahydrogen atom, an alkyl group, or an aryl group; an isocyanate group; oran epoxy group.

The methods and articles of this disclosure can be further understoodfrom the figures. FIG. 1 shows an embodiment of a method of thisdisclosure. In FIG. 1, assembled multi-layer construction comprisesfirst glass substrate 10, second glass substrate 20, and optical film30. Optical film 30 is held in place proximate to first glass substrate10 and second glass substrate 20 by clips 40. The assembled multi-layerconstruction is located in vacuum chamber 60. Pressure plates 50 arelocated on either side of the assembled multi-layer construction.Pressure plates 50 have O-rings 51, and compressed air tubes 55. Thisconstruction is subjected to process step A, which is the application ofa vacuum to the vacuum chamber 60 making the vacuum chamber 60′. Firstglass substrate 10, second glass substrate 20, and optical film 30 arein contact and are held together by pressure plates 50 by compressed airprovided by air tubes 55, the compressed air pressure being maintainedby O-rings 51. The optical film 30 is held by clips 40. The constructionis subjected to process step B which involves release of the vacuum fromvacuum chamber 60′, removal of the multi-layer assembly from the vacuumchamber and placement in an oven 70, and heated to a temperature of atleast 120° C., and then cooled to room temperature. First glasssubstrate 10, second glass substrate 20, and optical film 30 are incontact and are held together by pressure plates 50 by the compressedair provided by air tubes 55, the compressed air pressure beingmaintained by O-rings 51. The optical film 30 is held by clips 40.

FIG. 2 shows another embodiment of a method of this disclosure. In FIG.2, assembled multi-layer construction comprises first glass substrate110, second glass substrate 120, third glass substrate 180 and opticalfilms 130 and 190. Optical film 130 is held in place proximate to firstglass substrate 110 and second glass substrate 120 by clips 140, andoptical film 190 is held in place proximate to second glass substrate120 and third glass substrate 180 by clips 140. The assembledmulti-layer construction is located in vacuum chamber 160. Pressureplates 150 are located on either side of the assembled multi-layerconstruction. Pressure plates 150 have O-rings 151, and compressed airtubes 155. This construction is subjected to process step A, which isthe application of a vacuum to the vacuum chamber 160 making the vacuumchamber 160′. First glass substrate 110, optical film 130, second glasssubstrate 120, optical film 190, and third glass substrate 180 are incontact and are held together by pressure plates 150 by compressed airprovided by air tubes 155, the compressed air pressure being maintainedby O-rings 151. The optical films 130 and 190 are held by clips 140. Theconstruction is subjected to process step B which involves release ofthe vacuum from vacuum chamber 160′, removal of the multi-layer assemblyfrom the vacuum chamber and placement in an oven 170, and heated to atemperature of at least 120° C., and then cooled to room temperature.First glass substrate 110, optical film 130, second glass substrate 120,optical film 190, and third glass substrate 180 are in contact and areheld together by pressure plates 150 by compressed air provided by airtubes 155, the compressed air pressure being maintained by O-rings 151.The optical films 130 and 190 are held by clips 140.

FIG. 3 shows another embodiment of a method of this disclosure. In FIG.3, assembled multi-layer construction comprises first glass substrate210, second glass substrate 220, third glass substrate 280 and opticalfilms 230, 290, and 300. Optical film 230 is held in place proximate tofirst glass substrate 210 and second glass substrate 220 by clips 240,and optical films 290 and 300 are held in place proximate to secondglass substrate 220 and third glass substrate 280 by clips 240. Theassembled multi-layer construction is located in vacuum chamber 260.Pressure plates 250 are located on either side of the assembledmulti-layer construction. Pressure plates 250 have O-rings 251, andcompressed air tubes 255. This construction is subjected to process stepA, which is the application of a vacuum to the vacuum chamber 260 makingthe vacuum chamber 260′. First glass substrate 210, optical film 230,second glass substrate 220, optical film 290, optical film 300, andthird glass substrate 280 are in contact and are held together bypressure plates 250 by compressed air provided by air tubes 255, thecompressed air pressure being maintained by O-rings 251. The opticalfilms 230, 290, and 300 are held by clips 240. The construction issubjected to process step B which involves release of the vacuum fromvacuum chamber 260′, removal of the multi-layer assembly from the vacuumchamber and placement in an oven 270, and heated to a temperature of atleast 120° C., and then cooled to room temperature. First glasssubstrate 210, optical film 230, second glass substrate 220, opticalfilm 290, optical film 300, and third glass substrate 280 are in contactand are held together by pressure plates 250 by compressed air providedby air tubes 255, the compressed air pressure being maintained byO-rings 251. The optical films 230, 290, and 300 are held by clips 240.

This disclosure includes the following embodiments:

Among the embodiments are methods of preparing laminate articles.Embodiment 1 includes a method of preparing a laminate articlecomprising: providing a first glass substrate with a first major surfaceand a second major surface, wherein the second major surface is freefrom an adhesive layer; providing a second glass substrate with a firstmajor surface and a second major surface, wherein the first majorsurface is free from an adhesive layer; providing a first optical filmwith a first major surface and a second major surface comprising one ormore layers of polymeric material and wherein the first major surfaceand the second major surface are free from an adhesive layer; preparinga multi-layer construction by arranging the first glass substrate, thefirst optical film, and the second glass substrate such that the secondmajor surface of the first glass substrate is proximate to the firstmajor surface of the first optical film, and the second major surface ofthe first optical film is proximate to the first major surface of thesecond glass substrate; placing the multi-layer construction in a vacuumchamber; applying a vacuum to the vacuum chamber containing themulti-layer construction, such that the second major surface of thefirst glass substrate is in direct surface contact with the first majorsurface of the first optical film and the first major surface of thesecond glass substrate is in direct surface contact with the secondmajor surface of the first optical film; releasing the vacuum from thevacuum chamber; removing the multi-layer construction from the vacuumchamber and place the multi-layer construction in a device capable ofsupplying heat and/or pressure; raising and holding the temperature ofthe device capable of supplying heat and/or pressure to a temperature ator above the softening temperature of the polymeric material of thefirst and second major surfaces of the first optical film while applyinga pressure of greater than atmospheric pressure to the multi-layerconstruction; decreasing the temperature of the device capable ofsupplying heat and/or pressure to room temperature; and releasing thepressure of greater than atmospheric pressure to the multi-layerconstruction, to form a multi-layer article that is optically clear anddoes not show scattering of reflected light by the first optical film.

Embodiment 2 is the method of embodiment 1, further comprising:providing a third glass substrate with a first major surface and secondmajor surface, wherein the first major surface of the third glasssubstrate is free from an adhesive layer; providing a second opticalfilm with a first major surface and a second major surface, comprisingone or more layers of polymeric material and wherein the first majorsurface and the second major surface are free from an adhesive layer;and wherein preparing the multi-layer construction further comprisesarranging the second optical film and the third glass substrate suchthat the first major surface of the second optical film is proximate tothe second major surface of the second glass substrate and the secondmajor surface of the second optical film is proximate to the first majorsurface of the third glass substrate.

Embodiment 3 is the method of embodiment , further comprising: providinga third glass substrate with a first major surface and second majorsurface, wherein the first major surface of the third glass substrate isfree from an adhesive layer; providing a second optical film with afirst major surface and a second major surface, comprising one or morelayers of polymeric material and wherein the first major surface and thesecond major surface are free from an adhesive layer; providing a thirdoptical film with a first major surface and a second major surface,comprising one or more layers of polymeric material and wherein thefirst major surface and the second major surface are free from anadhesive layer; and wherein preparing the multi-layer constructionfurther comprises arranging the second optical film, the third opticalfilm, and the third glass substrate such that the first major surface ofthe second optical film is proximate to the second major surface of thesecond glass substrate, the first major surface of the third opticalfilm is proximate to the second major surface of the second opticalfilm, and the second major surface of the third optical film isproximate to the first major surface of the third glass substrate.

Embodiment 4 is the method of any of embodiments 1-3, wherein preparingthe multi-layer construction comprises placing the first and secondglass substrates and the first optical film in a frame wherein the framecomprises first and second plates such that the first plate is incontact with the first major surface of the first glass substrate andthe second plate is in contact with second major surface of the secondglass substrate.

Embodiment 5 is the method of embodiment 4, wherein each plate containsat least one orifice, wherein the orifice is connected to a source ofcompressed air pressure and wherein the orifice in the first plate is influid contact with the first glass substrate and the orifice in thesecond plate is in fluid contact with the second glass substrate, suchthat applying a pressure of greater than atmospheric pressure to themulti-layer construction comprises applying compressed air pressurethrough the orifices in the first and second plates.

Embodiment 6 is the method of any of embodiments 1-5, wherein the firstoptical film comprises a multi-layer polarizing film.

Embodiment 7 is the method of embodiment 6, the multi-layer polarizingfilm comprises alternating layers of polyethylene terephthalate andpolyethylene-naphthalate.

Embodiment 8 is the method of any of embodiments 1-7, wherein raisingand holding the temperature of the device capable of supplying heatand/or pressure comprises raising the temperature to at least 120° C.for at least 30 minutes.

Embodiment 9 is the method of any of embodiments 1-8, wherein thepressure of the device capable of supplying heat and/or pressure israised to at least 5 Kg/cm².

Embodiment 10 is a method of preparing a laminate article comprising:providing a first glass substrate with a first major surface and asecond major surface, wherein the second major surface is a treatedsurface that is free from an adhesive layer; providing a second glasssubstrate with a first major surface and a second major surface, whereinthe first major surface is a treated surface that is free from anadhesive layer; providing a first optical film with a first majorsurface and a second major surface comprising one or more layers ofpolymeric material and wherein the first major surface and the secondmajor surface are free from an adhesive layer; preparing a multi-layerconstruction by arranging the first glass substrate, the first opticalfilm, and the second glass substrate such that the second major surfaceof the first glass substrate is proximate to the first major surface ofthe first optical film, and the second major surface of the firstoptical film is proximate to the first major surface of the second glasssubstrate; placing the multi-layer construction in a vacuum chamber;applying a vacuum to the vacuum chamber containing the multi-layerconstruction, such that the second major surface of the first glasssubstrate is in direct surface contact with the first major surface ofthe first optical film and the first major surface of the second glasssubstrate is in direct surface contact with the second major surface ofthe first optical film; releasing the vacuum from the vacuum chamber;removing the multi-layer construction from the vacuum chamber and placethe multi-layer construction in a device capable of supplying heatand/or pressure; raising and holding the temperature of the devicecapable of supplying heat and/or pressure to a temperature at or abovethe softening temperature of the polymeric material of the first andsecond major surfaces of the first optical film while applying apressure of greater than atmospheric pressure to the multi-layerconstruction; decreasing the temperature of the device capable ofsupplying heat and/or pressure to room temperature; and releasing thepressure of greater than atmospheric pressure to the multi-layerconstruction, to form a multi-layer article that is optically clear anddoes not show scattering of reflected light by the first optical film.

Embodiment 11 is the method of embodiment 10, wherein the treatedsurface of the first glass substrate and the second glass substrate areprepared by a treatment comprising: providing a treatment solutioncomprising: at least one silane coupling agent; and a solvent; applyingthe treatment solution to the glass surface to form a continuous ordiscontinuous coating layer; and drying the continuous or discontinuouscoating layer.

Embodiment 12 is the method of embodiment 11, wherein the silanecoupling agent is of the general structure: Z₃Si-A-X wherein each Z isan alkyl or alkoxy group, with the proviso that at least one Z is analkoxy group; A is a divalent linking group comprising an alkylene,arylene, or aralkylene group; and X is a functional group selected froman amino group —NR¹ ₂ where each R¹ independently is a hydrogen atom, analkyl group, or an aryl group; an isocyanate group; or an epoxy group.

Embodiment 13 is the method of any of embodiments 10-12, furthercomprising: providing a third glass substrate with a first major surfaceand second major surface, wherein the first major surface of the thirdglass substrate is a treated surface that is free from an adhesivelayer; providing a second optical film with a first major surface and asecond major surface, comprising one or more layers of polymericmaterial and wherein the first major surface and the second majorsurface are free from an adhesive layer; and wherein preparing themulti-layer construction further comprises arranging the second opticalfilm and the third glass substrate such that the first major surface ofthe second optical film is proximate to the second major surface of thesecond glass substrate and the second major surface of the secondoptical film is proximate to the first major surface of the third glasssubstrate.

Embodiment 14 is the method of any of embodiments 10-12, furthercomprising: providing a third glass substrate with a first major surfaceand second major surface, wherein the first major surface of the thirdglass substrate is a treated surface that is free from an adhesivelayer; providing a second optical film with a first major surface and asecond major surface, comprising one or more layers of polymericmaterial and wherein the first major surface and the second majorsurface are free from an adhesive layer; providing a third optical filmwith a first major surface and a second major surface, comprising one ormore layers of polymeric material and wherein the first major surfaceand the second major surface are free from an adhesive layer; andwherein preparing the multi-layer construction further comprisesarranging the second optical film, the third optical film, and the thirdglass substrate such that the first major surface of the second opticalfilm is proximate to the second major surface of the second glasssubstrate, the first major surface of the third optical film isproximate to the second major surface of the second optical film, andthe second major surface of the third optical film is proximate to thefirst major surface of the third glass substrate.

Embodiment 15 is the method of any of embodiments 10-14, whereinpreparing the multi-layer construction comprises placing the first andsecond glass substrates and the first optical film in a frame whereinthe frame comprises first and second plates such that the first plate isin contact with the first major surface of the first glass substrate andthe second plate is in contact with second major surface of the secondglass substrate.

Embodiment 16 is the method of embodiment 15, wherein each platecontains at least one orifice, wherein the orifice is connected to asource of compressed air pressure and wherein the orifice in the firstplate is in fluid contact with the first glass substrate and the orificein the second plate is in fluid contact with the second glass substrate,such that applying a pressure of greater than atmospheric pressure tothe multi-layer construction comprises applying compressed air pressurethrough the orifices in the first and second plates.

Embodiment 17 is the method of any of embodiments 10-16, wherein thefirst optical film comprises a multi-layer polarizing film.

Embodiment 18 is the method of embodiment 17, wherein the multi-layerpolarizing film comprises alternating layers of polyethyleneterephthalate and polyethylene-naphthalate.

Embodiment 19 is the method of any of embodiments 10-18, wherein raisingand holding the temperature of the device capable of supplying heatand/or pressure comprises raising the temperature to at least 120° C.for at least 30 minutes.

Embodiment 20 is the method of any of embodiments 10-19, wherein thepressure of the device capable of supplying heat and/or pressure israised to at least 5 Kg/cm².

Also disclosed are multi-layer articles. Embodiment 21 includes amulti-layer article comprising: a first glass substrate with a firstmajor surface and a second major surface; a second glass substrate witha first major surface and a second major surface; and a first opticalfilm with a first major surface and a second major surface comprisingone or more layers of polymeric material, wherein the second majorsurface of the first glass substrate is interfacially bonded to thefirst major surface of the first optical film, wherein the interfacialbond is free from an adhesive layer, and wherein the second majorsurface of the first optical film is interfacially bonded with the firstmajor surface of the second glass substrate, wherein the interfacialbond is free from an adhesive layer, and wherein the second majorsurface to the first glass substrate and the first major surface of thesecond glass substrate is a treated or untreated surface, wherein thetreated surface comprises a silane coupling agent-treated surface, andwherein the multi-layer article is optically clear and does not showscattering of reflected light by the first optical film.

Embodiment 22 is the multi-layer article of embodiment 21, wherein thearticle further comprises: a second optical film with a first majorsurface and a second major surface; and a third glass substrate with afirst major surface and a second major surface, wherein the second majorsurface of the second glass substrate is interfacially bonded to thefirst major surface of the second optical film, wherein the interfacialbond is free from an adhesive layer, and wherein the second majorsurface of the second optical film is interfacially bonded with thefirst major surface of the third glass substrate, wherein theinterfacial bond is free from an adhesive layer, and wherein the secondmajor surface of the second glass substrate and the first major surfaceof the third glass substrate is a treated or untreated surface, whereinthe treated surface comprises a silane coupling agent-treated surface,and wherein the multi-layer article is optically clear and does not showscattering of reflected light by the optical films.

Embodiment 23 is the multi-layer article of embodiment 21, wherein thearticle further comprises: a second optical film with a first majorsurface and a second major surface; a third optical film with a firstmajor surface and a second major surface; and a third glass substratewith a first major surface and a second major surface, wherein thesecond major surface of the second glass substrate is interfaciallybonded to the first major surface of the second optical film, whereinthe interfacial bond is free from an adhesive layer, and wherein thesecond major surface of the second optical film is interfacially bondedwith the first major surface of the third optical film, wherein theinterfacial bond is free from an adhesive layer, and wherein the secondmajor surface of the third optical film is interfacially bonded to thefirst major surface of the third glass substrate, wherein the secondmajor surface of the second glass substrate and the first major surfaceof the third glass substrate is a treated or untreated surface, whereinthe treated surface comprises a silane coupling agent-treated surface,and wherein the multi-layer article is optically clear and does not showscattering of reflected light by the optical films.

Embodiment 24 is the multi-layer article of any of embodiments 21-23,wherein the first optical film comprises a multi-layer polarizing film.

Embodiment 25 is the multi-layer article of embodiment 24, wherein themulti-layer polarizing film comprises alternating layers of polyethyleneterephthalate and polyethylene-naphthalate.

Embodiment 26 is the multi-layer article of any of embodiments 21-25,wherein the second major surface of the first glass substrate and thefirst major surface of the second glass substrate comprises a treatedsurface, wherein the treated surface comprises a treated surface treatedwith a silane coupling agent with the general structure: Z₃Si-A-Xwherein each Z is an alkyl or alkoxy group, with the proviso that atleast one Z is an alkoxy group; A is a divalent linking group comprisingan alkylene, arylene, or aralkylene group; and X is a functional groupselected from an amino group —NR¹ ₂ where each R¹ independently is ahydrogen atom, an alkyl group, or an aryl group; an isocyanate group; oran epoxy group.

EXAMPLES

These examples are merely for illustrative purposes only and are notmeant to be limiting on the scope of the appended claims. All parts,percentages, ratios, etc. in the examples and the rest of thespecification are by weight, unless noted otherwise. Solvents and otherreagents used were obtained from Sigma-Aldrich Chemical Company;Milwaukee, Wisconsin unless otherwise noted. The following abbreviationsare used: mm=millimeters; Pa=Pascals; min=minutes; hr=hour; Kg=kilogram;cm=centimeter.

Table of Abbreviations Abbreviation or Trade Designation DescriptionGlass Plate AR glass plate with a diameter of 300 mm and a thickness of0.7 mm commercially available from Schott as BOROFLOAT. AP Film Amultilayer optical film reflective polarizer, commercially availablefrom 3M Company as APF-T35. PFS “Polarizer Film Substrate”, a glassplate as described above without the AR coating. PF Polarizer filmcommercially available from Sanritz Corporation as HLC2-5618. Plate filmFilm commercially available from Teijin as TEIJIN W142 QWP. OCA 3MOPTICALLY CLEAR ADHESIVE 8141 commercially available from 3M Company.

Test Methods Orange Peel Testing

Orange Peel testing was carried out by observing the reflected imagegenerated when a straight body fluorescent tube was shone on theconstructions described below. The presence or absence of Orange Peelwas easily visibly perceived. The result of the test is reported as“Good” if no Orange Peel is observed or “NG” if Orange Peel is observed.

Bond Testing

Bonding testing refers to whether the bonding adhesion between layers ishigh enough to withstand the water jet cutting process. The data arepresented as “Good” if no de-lamination occurs during the water jetcutting process; “Marginal” if the water jet cutting was successful butsome delamination occurs during the water jet cutting process; or “NG”if the construction is unable to withstand water jet cutting.

Warpage Testing

Warpage refers to the flatness of the stack of with a diameter of 300 mmprior to water jet cutting as detected by visibly observation. The dataare presented as “Good” if no warpage is observed; “Marginal” if somewarpage is observed; or “NG” if the construction is highly warped.

Examples 1-2 and Comparative Examples C1-C2

Examples of a flat lens optical article that includes a laminated stackof 3 glass plates and 3 optical films. In each case the formed opticalarticle was 34 mm in diameter and about 2.5 mm thick. The articles weremade by assembling and processing a laminate stack construction.

Generalized Assembly and Processing of Laminate Stack Construction:

For each article laminate stack assemblies were arranged in thesequence: Glass Plate/AP Film/PFS/PF/Plate film/Glass Plate.

The general procedure for assembling and processing the laminate stackassemblies was as follows:

-   1) Each film was attached to an individual ring frame.-   2) The glass plates and films with ring frames were placed in    sequence in a vacuum chamber between two 30 mm thick aluminum    pressing plates with O rings to seal the aluminum pressing plates    against the glass plates, the entire construction being held    together with bolts between the two aluminum pressing plates.-   3) The vacuum chamber was pumped down to a pressure of 50 Pa and the    layers of the assembly were pressed together with the pressing    plates.-   4) Break the vacuum and take out the stack with the pressing plates.

5) Put the stack all together into an air-circulating oven for 1 hr.

-   6) Take out the stack and allow to cool to room temperature.-   7) Cut out the stack along glass edge.-   8) Water jet to cut into final diameter (34 mm).

Comparative Example C1

For Comparative Example C1, an OCA was used to bond the assembly suchthat the assembly has the sequence: Glass Plate/OCA/APFilm/OCA/PFS/OCA/PF/OCA/Plate film/OCA/Glass Plate.

The resultant construction failed the Orange Peel test (described above)and was not further tested.

Examples 1-2 and Comparative Example C2

For Examples 1-2 and Comparative Example C2, no OCA was used, and thedifferences are that for Examples 1 and 2, compressed air pressure (5Kg/cm²) was applied through inlets in the aluminum pressing platesagainst the two outer glass plates of the construction immediatelybefore the vacuum in the vacuum chamber was broken. In ComparativeExample C2 no compressed air pressure was applied. In Example 1 andComparative Example C2, the stack was heated at a temperature of 150° C.for 1 hour, in Example 2 the stack was heated to a temperature of 100°C. for 1 hour. A summary of these conditions as well the results ofOrange Peel, Bonding, and Warpage testing (described above) arepresented in Table 1.

TABLE 1 Compressed Oven Air Pressure Conditions Applied Example (° C.for 1 hr) (Kg/cm²) Orange Peel Bonding Warpage 1 150 5 Good GoodMarginal 2 100 5 Good Marginal Good C2 150 0 NG NG NA NA = NotApplicable

What is claimed is:
 1. A method of preparing a laminate article comprising: providing a first glass substrate with a first major surface and a second major surface, wherein the second major surface is free from an adhesive layer; providing a second glass substrate with a first major surface and a second major surface, wherein the first major surface is free from an adhesive layer; providing a first optical film with a first major surface and a second major surface comprising one or more layers of polymeric material and wherein the first major surface and the second major surface are free from an adhesive layer; preparing a multi-layer construction by arranging the first glass substrate, the first optical film, and the second glass substrate such that the second major surface of the first glass substrate is proximate to the first major surface of the first optical film, and the second major surface of the first optical film is proximate to the first major surface of the second glass substrate; placing the multi-layer construction in a vacuum chamber; applying a vacuum to the vacuum chamber containing the multi-layer construction, such that the second major surface of the first glass substrate is in direct surface contact with the first major surface of the first optical film and the first major surface of the second glass substrate is in direct surface contact with the second major surface of the first optical film; releasing the vacuum from the vacuum chamber; removing the multi-layer construction from the vacuum chamber and place the multi-layer construction in a device capable of supplying heat and/or pressure; raising and holding the temperature of the device capable of supplying heat and/or pressure to a temperature at or above the softening temperature of the polymeric material of the first and second major surfaces of the first optical film while applying a pressure of greater than atmospheric pressure to the multi-layer construction; decreasing the temperature of the device capable of supplying heat and/or pressure to room temperature; and releasing the pressure of greater than atmospheric pressure to the multi-layer construction, to form a multi-layer article that is optically clear and does not show scattering of reflected light by the first optical film.
 2. The method of claim 1, further comprising: providing a third glass substrate with a first major surface and second major surface, wherein the first major surface of the third glass substrate is free from an adhesive layer; providing a second optical film with a first major surface and a second major surface, comprising one or more layers of polymeric material and wherein the first major surface and the second major surface are free from an adhesive layer; and wherein preparing the multi-layer construction further comprises arranging the second optical film and the third glass substrate such that the first major surface of the second optical film is proximate to the second major surface of the second glass substrate and the second major surface of the second optical film is proximate to the first major surface of the third glass substrate.
 3. The method of claim 1, further comprising: providing a third glass substrate with a first major surface and second major surface, wherein the first major surface of the third glass substrate is free from an adhesive layer; providing a second optical film with a first major surface and a second major surface, comprising one or more layers of polymeric material and wherein the first major surface and the second major surface are free from an adhesive layer; providing a third optical film with a first major surface and a second major surface, comprising one or more layers of polymeric material and wherein the first major surface and the second major surface are free from an adhesive layer; and wherein preparing the multi-layer construction further comprises arranging the second optical film, the third optical film, and the third glass substrate such that the first major surface of the second optical film is proximate to the second major surface of the second glass substrate, the first major surface of the third optical film is proximate to the second major surface of the second optical film, and the second major surface of the third optical film is proximate to the first major surface of the third glass substrate.
 4. The method of claim 1, wherein preparing the multi-layer construction comprises placing the first and second glass substrates and the first optical film in a frame wherein the frame comprises first and second plates such that the first plate is in contact with the first major surface of the first glass substrate and the second plate is in contact with second major surface of the second glass substrate.
 5. The method of claim 4, wherein each plate contains at least one orifice, wherein the orifice is connected to a source of compressed air pressure and wherein the orifice in the first plate is in fluid contact with the first glass substrate and the orifice in the second plate is in fluid contact with the second glass substrate, such that applying a pressure of greater than atmospheric pressure to the multi-layer construction comprises applying compressed air pressure through the orifices in the first and second plates.
 6. The method of claim 1, wherein raising and holding the temperature of the device capable of supplying heat and/or pressure comprises raising the temperature to at least 120° C. for at least 30 minutes.
 7. A method of preparing a laminate article comprising: providing a first glass substrate with a first major surface and a second major surface, wherein the second major surface is a treated surface that is free from an adhesive layer; providing a second glass substrate with a first major surface and a second major surface, wherein the first major surface is a treated surface that is free from an adhesive layer; providing a first optical film with a first major surface and a second major surface comprising one or more layers of polymeric material and wherein the first major surface and the second major surface are free from an adhesive layer; preparing a multi-layer construction by arranging the first glass substrate, the first optical film, and the second glass substrate such that the second major surface of the first glass substrate is proximate to the first major surface of the first optical film, and the second major surface of the first optical film is proximate to the first major surface of the second glass substrate; placing the multi-layer construction in a vacuum chamber; applying a vacuum to the vacuum chamber containing the multi-layer construction, such that the second major surface of the first glass substrate is in direct surface contact with the first major surface of the first optical film and the first major surface of the second glass substrate is in direct surface contact with the second major surface of the first optical film; releasing the vacuum from the vacuum chamber; removing the multi-layer construction from the vacuum chamber and place the multi-layer construction in a device capable of supplying heat and/or pressure; raising and holding the temperature of the device capable of supplying heat and/or pressure to a temperature at or above the softening temperature of the polymeric material of the first and second major surfaces of the first optical film while applying a pressure of greater than atmospheric pressure to the multi-layer construction; decreasing the temperature of the device capable of supplying heat and/or pressure to room temperature; and releasing the pressure of greater than atmospheric pressure to the multi-layer construction, to form a multi-layer article that is optically clear and does not show scattering of reflected light by the first optical film.
 8. The method of claim 7, wherein the treated surface of the first glass substrate and the second glass substrate are prepared by a treatment comprising: providing a treatment solution comprising: at least one silane coupling agent; and a solvent; applying the treatment solution to the glass surface to form a continuous or discontinuous coating layer; and drying the continuous or discontinuous coating layer.
 9. The method of claim 8, wherein the silane coupling agent is of the general structure: Z₃Si-A-X wherein each Z is an alkyl or alkoxy group, with the proviso that at least one Z is an alkoxy group; A is a divalent linking group comprising an alkylene, arylene, or aralkylene group; and X is a functional group selected from an amino group —NR¹ ₂ where each R¹ independently is a hydrogen atom, an alkyl group, or an aryl group; an isocyanate group; or an epoxy group.
 10. The method of claim 7, further comprising: providing a third glass substrate with a first major surface and second major surface, wherein the first major surface of the third glass substrate is a treated surface that is free from an adhesive layer; providing a second optical film with a first major surface and a second major surface, comprising one or more layers of polymeric material and wherein the first major surface and the second major surface are free from an adhesive layer; and wherein preparing the multi-layer construction further comprises arranging the second optical film and the third glass substrate such that the first major surface of the second optical film is proximate to the second major surface of the second glass substrate and the second major surface of the second optical film is proximate to the first major surface of the third glass substrate.
 11. The method of claim 7, further comprising: providing a third glass substrate with a first major surface and second major surface, wherein the first major surface of the third glass substrate is a treated surface that is free from an adhesive layer; providing a second optical film with a first major surface and a second major surface, comprising one or more layers of polymeric material and wherein the first major surface and the second major surface are free from an adhesive layer; providing a third optical film with a first major surface and a second major surface, comprising one or more layers of polymeric material and wherein the first major surface and the second major surface are free from an adhesive layer; and wherein preparing the multi-layer construction further comprises arranging the second optical film, the third optical film, and the third glass substrate such that the first major surface of the second optical film is proximate to the second major surface of the second glass substrate, the first major surface of the third optical film is proximate to the second major surface of the second optical film, and the second major surface of the third optical film is proximate to the first major surface of the third glass substrate.
 12. The method of claim 7, wherein preparing the multi-layer construction comprises placing the first and second glass substrates and the first optical film in a frame wherein the frame comprises first and second plates such that the first plate is in contact with the first major surface of the first glass substrate and the second plate is in contact with second major surface of the second glass substrate.
 13. The method of claim 12, wherein each plate contains at least one orifice, wherein the orifice is connected to a source of compressed air pressure and wherein the orifice in the first plate is in fluid contact with the first glass substrate and the orifice in the second plate is in fluid contact with the second glass substrate, such that applying a pressure of greater than atmospheric pressure to the multi-layer construction comprises applying compressed air pressure through the orifices in the first and second plates.
 14. The method of claim 7, wherein raising and holding the temperature of the device capable of supplying heat and/or pressure comprises raising the temperature to at least 120° C. for at least 30 minutes.
 15. A multi-layer article comprising: a first glass substrate with a first major surface and a second major surface; a second glass substrate with a first major surface and a second major surface; and a first optical film with a first major surface and a second major surface comprising one or more layers of polymeric material, wherein the second major surface of the first glass substrate is interfacially bonded to the first major surface of the first optical film, wherein the interfacial bond is free from an adhesive layer, and wherein the second major surface of the first optical film is interfacially bonded with the first major surface of the second glass substrate, wherein the interfacial bond is free from an adhesive layer, and wherein the second major surface to the first glass substrate and the first major surface of the second glass substrate is a treated or untreated surface, wherein the treated surface comprises a silane coupling agent-treated surface, and wherein the multi-layer article is optically clear and does not show scattering of reflected light by the first optical film.
 16. The multi-layer article of claim 15, wherein the article further comprises: a second optical film with a first major surface and a second major surface; and a third glass substrate with a first major surface and a second major surface, wherein the second major surface of the second glass substrate is interfacially bonded to the first major surface of the second optical film, wherein the interfacial bond is free from an adhesive layer, and wherein the second major surface of the second optical film is interfacially bonded with the first major surface of the third glass substrate, wherein the interfacial bond is free from an adhesive layer, and wherein the second major surface of the second glass substrate and the first major surface of the third glass substrate is a treated or untreated surface, wherein the treated surface comprises a silane coupling agent-treated surface, and wherein the multi-layer article is optically clear and does not show scattering of reflected light by the optical films.
 17. The multi-layer article of claim 15, wherein the article further comprises: a second optical film with a first major surface and a second major surface; a third optical film with a first major surface and a second major surface; and a third glass substrate with a first major surface and a second major surface, wherein the second major surface of the second glass substrate is interfacially bonded to the first major surface of the second optical film, wherein the interfacial bond is free from an adhesive layer, and wherein the second major surface of the second optical film is interfacially bonded with the first major surface of the third optical film, wherein the interfacial bond is free from an adhesive layer, and wherein the second major surface of the third optical film is interfacially bonded to the first major surface of the third glass substrate, wherein the second major surface of the second glass substrate and the first major surface of the third glass substrate is a treated or untreated surface, wherein the treated surface comprises a silane coupling agent-treated surface, and wherein the multi-layer article is optically clear and does not show scattering of reflected light by the optical films.
 18. The multi-layer article of claim 15, wherein the first optical film comprises a multi-layer polarizing film.
 19. The multi-layer article of claim 18, wherein the multi-layer polarizing film comprises alternating layers of polyethylene terephthalate and polyethylene-naphthalate
 20. The multi-layer article of claim 15, wherein the second major surface of the first glass substrate and the first major surface of the second glass substrate comprises a treated surface, wherein the treated surface comprises a treated surface treated with a silane coupling agent with the general structure: Z₃Si-A-X wherein each Z is an alkyl or alkoxy group, with the proviso that at least one Z is an alkoxy group; A is a divalent linking group comprising an alkylene, arylene, or aralkylene group; and X is a functional group selected from an amino group —NR¹ ₂ where each R¹ independently is a hydrogen atom, an alkyl group, or an aryl group; an isocyanate group; or an epoxy group. 